How Much do Pressure Drops Impact Your Compressed Air System?

Most people would likely be surprised that the biggest single cost associated with making compressed air isn’t the capital costs associated with the compressor but rather the energy required to power the compressor. With that in mind, and even regardless of this fact, it makes sense to keep energy costs down.

One way to do that is to avoid compressed air system pressure drops by optimizing the system’s piping configuration. When it comes to piping we often think of pressure drops, and the first question that comes to mind should be ‘whose version of the classic ska song Pressure Drop is better, the original by Toots & The Maytals or The Clash’s cover?’ The second should be ‘does my piping system design optimize transfer of compressed air at the desired flow and pressure to the point of use?’ Increasing the size of your pipe from 2” to 3” can reduce pressure drop up to 50 percent. Shortening the distance that air has to travel can further reduce pressure drops by about 30 percent.

Additionally, the more flow you try to put through a pipe, the greater the pressure drop will be. Pressure drop in a piping system increases with the square of the Increase in flow meaning if you double the flow, the pressure drop will increase four times what is was.  Air distribution piping should be large enough in diameter to minimize pressure drop.

Each 2 psig reduction cuts energy consumption 1 percent. Check the pressures you are achieving and don’t keep turning up the pressure to compensate for leaks or drops in pressure due to piping problems or clogged filters. Rather, fix the leaks and you likely will be able to drop the pressure.

An ounce of prevention beats a pound of cure, so be proactive and take a look at your piping system.  A clean, dry pipe means you have good quality air and should have no corrosion issues. Dust in the pipe is caused by particles in your air. If you don’t filter it, or if your filter is clogged, you'll have pressure drops and increase the risk of contaminating your end product (as well as that whole spending more money that you have to thing).